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Summary of Contents for Conductix-Wampfler 0365
- Page 1 Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 MAL0300-0004c-EN www.conductix.com translated document page 1 of 70...
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Page 2: Table Of Contents
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 Contents General notes ..................................5 Information about these assembly instructions ......................5 Limitation of liability ..............................5 Copyright ..................................6 Spare parts .................................. 6 Material defects ................................6 Technical support ................................ - Page 3 Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 3.5.6 Poor horizontal alignment between the crane beam and the track beam ..............21 3.5.7 Poor vertical alignment between the crane beam and track beam ................21 Product Description and Mode of Operation .......................... 22 Overview of the festoon system ..........................
- Page 4 Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 6.3.12 Installation of wind retaining device ........................... 46 6.3.13 Adjusting the running gear ............................47 Testing and commissioning ............................48 6.4.1 Commissioning checklist ............................49 Operation ....................................51 Safety ..................................
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Page 5: General Notes
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 General notes 1.1 Information about these assembly instructions These assembly instructions allow the safe, efficient use of the festoon system. The assembly instructions are a component of the festoon system and must be kept in the immediate vicinity of the festoon system and accessible to personnel at all times. -
Page 6: Copyright
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 1.3 Copyright These assembly instructions are subject to copyright and exclusively intended for internal use. Provision of the assembly instructions to third parties, duplications in any form - even in part - as well as the reuse and/or disclosure of their content are not permitted without the written approval of the manufacturer, except for internal use. -
Page 7: Safety Instructions
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 Safety instructions 2.1 General safety information Safety and hazard information is identified in these assembly instructions by symbols. Signal words are used in these safety instructions to indicate the degree of hazard. Always observe safety and hazard information and work carefully to avoid accidents, bodily harm or property damage! …... -
Page 8: Personnel Requirements
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 2.2 Personnel requirements 2.2.1 Qualifications Injury due to insufficient qualifications! Improper use can result in serious injury to person and property. → Allow only qualified personnel to carry out all activities! -
Page 9: Personal Protective Equipment
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 2.3 Personal protective equipment Always wear: For all work, always wear: Work safety clothing is close-fitting work clothing that has a low tearing strength with tight arms and no parts that protrude. -
Page 10: Intended Use
The festoon system is exclusively designed and built for the intended use described here. Festoon systems program 0365, 0370 and 0375 are intended for the installation and operation of an electrical supply line for track- based mobile consumers, such as cranes and lifting gears in industrial environment. Other uses are only permitted after written approval by Conductix-Wampfler. -
Page 11: Protective Measures To Be Taken By The Operator/User
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 2.5 Protective measures to be taken by the operator/user The festoon system is used in an industrial setting. The operator of the festoon system is thus subject to legal requirements related to workplace safety. -
Page 12: Particular Risks
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 2.6 Particular risks The following section lists residual risks determined based on a risk assessment. Follow the safety instructions listed here and the warnings in other sections of these assembly instructions in order to reduce ... - Page 13 Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 Danger of burning! Danger of burning when using insufficiently dimensioned cables! → Always comply with the necessary cross-section of cables. WARNING! Danger of tripping on projecting parts! When working on the festoon system, there is a risk of tripping.
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Page 14: Behavior In Case Of Accidents And Malfunctions
Involve authorized personnel for maintenance and repair. Shut down the system and secure it against unauthorized, unintentional, and/or erroneous activation. If injury to person and property can occur during breakdowns then Conductix-Wampfler must be informed immediately. MAL0300-0004c-EN www.conductix.com... -
Page 15: Technical Specifications
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 Technical specifications 3.1 General information Designation Value Notes Max. load capacity 350 - 800 kg Depending on the festoon product line selected Max. travel speed 210 - 300 m/min... -
Page 16: Type Plate
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 3.4 Type plate The type plate is on the end clamp and includes the following information: Model Year of construction Order number Manufacturer Manufacturer address ... -
Page 17: Smoothing Of Welded Track Beams
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 3.5.1 Smoothing of welded track beams Bumps and uneven areas on all sides of the welded track beams are to be ground smooth for a length of 100 mm. -
Page 18: Girder Joint For Non-Welded Track Beams
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 3.5.3 Girder joint for non-welded track beams For non-welded girder joints, the gap between beams may be at most 8 mm. The cut is at a 45° angle. - Page 19 Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 MAL0300-0004c-EN www.conductix.com translated document page 19 of 70...
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Page 20: Horizontal Deviation Of Track Beams
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 3.5.4 Horizontal deviation of track beams The horizontal deviation over the length of the track beam may not exceed ±5 mm. For lengths shorter than 2 m, deviation may not exceed ±2 mm. -
Page 21: Poor Horizontal Alignment Between The Crane Beam And The Track Beam
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 3.5.6 Poor horizontal alignment between the crane beam and the track beam The horizontal alignment gap between the crane beam and track beam must not exceed ±7.5 mm. This tolerance should include a possible alignment deviation of the trolley winch. -
Page 22: Product Description And Mode Of Operation
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 Product Description and Mode of Operation 4.1 Overview of the festoon system 5, 7 Fig. 10: Overview of the festoon system 1) End clamp 6) Towing rope 2) Cable trolley... -
Page 23: Brief Description
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 4.2 Brief description A festoon system consists of the end clamp, cable trolley, towing trolley or towing clamp, and cables. A towing arm (not included) couples the towing trolley or towing clamp to the mobile consumer. The towing trolley pulls and/or pushes the following cable trolley. - Page 24 Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 Towing trolley consisting of: Running gear Centre plate Cable support Clamping bar Buffer / Buffer unit Anti-lift plates Towing window Fig. 13: Towing trolley Towing clamp consisting of: ...
- Page 25 Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 Side shield consisting of: Side shield plate Main roller (HTR) Horizontal guide roller (HFR) Anti-lift roller (GDR Fig. 16: Side shield Towing rope consisting of: Shackle Steel cable Fig.
- Page 26 Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 Damping device consisting of: Fastening bracket Shock cord Fig. 20: Damping device Wind retaining device consisting of: Shock cord Fastening to tension cable Round cable clamp (not included) Fig.
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Page 27: Working And Danger Areas
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 4.4 Working and danger areas The following illustration shows the working area of the festoon system. There is a danger of injury from moving parts in this area. -
Page 28: Operating Modes
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 4.5 Operating modes The festoon system can be operated in one of two modes: Automatic operation Manual operation 4.5.1 Automatic operation The standard operating mode is automatic operation, in which the festoon system is operated via the consumer's controller. In this mode, no person may be in or under the working area of the festoon system. -
Page 29: Transport, Packaging And Storage
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 Transport, packaging and storage 5.1 Transport 5.1.1 Safety instructions for transport Danger of death due to hanging loads! When lifting loads, there is a danger of death from falling parts or those swinging out of control. -
Page 30: Packaging
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 5.2 Packaging The individual packaged parts must be packed according to the transport conditions to be expected. Only environmentally friendly materials have been used for packaging. The packaging must protect the individual components from transport damages, corrosion, and other damage until installation. -
Page 31: Installation And Commissioning
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 Installation and commissioning 6.1 Safety Personnel: Installation and commissioning may only be carried out by specially trained technicians. Wear the following protective gear during all work of installation and commissioning: Work safety clothing ... -
Page 32: Preparation
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 6.2 Preparation Tools needed: Drilling machine Metal drill Crescent wrench Corrosion protection Lubricant Gauges 6.3 Installation Personnel: May only be carried out by trained technicians ... -
Page 33: Mounting A Pre-Assembled Festoon System
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 The use of pre-assembled festoon systems (with pre-attached cables on the cable trolley) will save a significant amount of time and money. NOTICE! → Loads are to be carefully fastened onto suitable hoists or load-carrying devices that are technically intact and have sufficient load capacity. -
Page 34: Mounting A Towing Clamp
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 6.3.2 Mounting a towing clamp → Height differences between the cable trolley buffer and the tappet clamp buffer or tappet clamp deflector must be equalized using a filler plate. -
Page 35: Mounting The Towing Trolley
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 6.3.3 Mounting the towing trolley → Using a plastic block to hold the towing arm in the towing trolley window improves the longevity and reliability of the festoon system. -
Page 36: Mounting The End Clamp
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 6.3.5 Mounting the end clamp → Height differences Δh greater than 5 mm between the trolley and the end clamp buffer must be compensated for by installing a filler plate. -
Page 37: Arrangement Of Round Cables
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 6.3.6 Arrangement of round cables Danger of burning! Danger of burning when using insufficiently dimensioned cables! → Always comply with the necessary cross-section of cables. WARNING! Danger due to improper installation of cables! Improper arrangement of cables in the cable packet and in loops can damage the cables and lead to death from electric shock. - Page 38 Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 → The clamping braces of the layers must be screwed into place tightly enough to prevent thin cables from being pulled through during operation, while still not damaging the cables due to excessive clamping. If necessary, clamping pieces can be used.
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Page 39: Arrangement Of Flat Cables
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 6.3.7 Arrangement of flat cables Danger of burning! Danger of burning when using insufficiently dimensioned cables! → Always comply with the necessary cross-section of cables. WARNING! Danger due to improper installation of cables! Improper arrangement of cables in the cable packet and in loops can damage the cables and lead to electrocution. -
Page 40: Mounting Round Cable Clamps
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 6.3.8 Mounting round cable clamps → Improper positioning of the round cable clamps can lead to damage of the cables and festoon system. → Improper mounting and arrangement of cables in the round cable clamp can damage the cables and CAUTION! the cable trolley system. - Page 41 Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 Ensure that the inner cables can move freely in the round cable clamp window. If spacers need to be used (in order to prevent turning and superimposition of cables), insert them before closing the cable clamp.
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Page 42: Mounting Flat Cable Clamps
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 6.3.9 Mounting flat cable clamps → Clamp the uppermost cables in the flat cable clamp. The other cables must be freely movable in the flat cable clamp window. -
Page 43: Mounting The Towing Rope
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 6.3.10 Mounting the towing rope It is important to ensure that the shackles and thimbles can move freely once assembled. NOTICE! The towing rope is installed between two cable trolleys, end clamps, and cable trolley, or between a towing trolley/clamp and a cable trolley. -
Page 44: Damping Device
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 6.3.11 Damping device → Be sure that the fastening eyes can still move slightly after tightening of the lock nut, or in the case of slack shock cords, can tip over alone. - Page 45 Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 Fig. 43: Damping device with two shock cords, for main roller diameters of 80, 100, 112, 125, and 160 mm Fig. 44: Damping device with four shock cords, for main roller diameters of 80, 100, 112, 125, and 160 mm Fig.
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Page 46: Installation Of Wind Retaining Device
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 6.3.12 Installation of wind retaining device The installation is preferably made when the motorized festoon system is retracted. NOTICE! The wind retaining device provides a direct connection between towing rope and cable package, so that even under strong lateral forces, like strong winds, the towing rope can no longer drift out to the side. -
Page 47: Adjusting The Running Gear
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 6.3.13 Adjusting the running gear The guide rollers of the trolleys are delivered set to the maximum width tolerance indicated for the track beams at the time of ordering. -
Page 48: Testing And Commissioning
Free access to the system must be provided. After commissioning is complete, Conductix-Wampfler will receive an authorized final acceptance protocol from the operator, in which it is logged that the system corresponds to the requirements. -
Page 49: Commissioning Checklist
This checklist should be used as a guideline to ensure the safety operation of the festoon system. The operating instructions are intended for qualified specialists who install the festoon systems, operate them and who are familiar with the requirements regarding work safety and accident prevention. If Conductix-Wampfler performed the commissioning, the final acceptance protocol on the last page should be filled out. Customer: Cust. - Page 50 Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 Commissioning Checklist Inspections on deactivated system Not OK The travel length of the trolley corresponds to the project-specific technical documentation. The storage length of the festoon system corresponds to the project-specific technical documentation.
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Page 51: Operation
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 Operation 7.1 Safety Danger of death due to hanging loads! When lifting loads, there is a danger of death from falling parts or those swinging out of control. -
Page 52: Function
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 Danger of crushing! When moving the festoon system, there is a danger of crushing limbs between the buffer and buffer plate, as well as between the running gear and the track beam. -
Page 53: Maintenance And Service
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 Maintenance and service 8.1 Safety Danger of injury due to improperly executed maintenance tasks! Improper maintenance can result in serious injury to person and property. → Before starting work, ensure sufficient space for assembly. -
Page 54: Maintenance / Inspection Plan
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 8.2 Maintenance / inspection plan The next sections describe the maintenance tasks required for optimum, trouble-free operation. If regular inspections reveal increased wear, the corresponding maintenance intervals should be shortened in accordance with the actual signs of wear. - Page 55 Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 MAL0300-0004c-EN www.conductix.com translated document Page 55 of 70...
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Page 56: Inspection On Deactivated System
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 8.2.1 Inspection on deactivated system → Protect the festoon system from inadvertent activation. → Safety devices that were removed during inspection of the resting system must be immediately remounted and checked after completion of work. -
Page 57: Inspection Of Towing Ropes And Criteria For Replacement
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 8.2.2 Inspection of towing ropes and criteria for replacement → In case of defect, towing ropes must be removed from use immediately. They must be replaced. CAUTION! A towing rope must be replaced if one or more of the following criteria are fulfilled: 1. -
Page 58: Inspection On Moving System
Should problems be identified during inspection, service work is urgent. 8.2.4 Logging The results of inspections as well as the remedies performed are to be documented in written reports. Conductix-Wampfler must be informed immediately of defects and malfunctions during the test phase and the warranty period. MAL0300-0004c-EN www.conductix.com... -
Page 59: Maintenance Of The Festoon System
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 8.2.5 Maintenance of the festoon system → Turn off power supply and ensure that no inadvertent activation is possible. → When installation tasks are carried out above eye level, use proper climbing aids and working platforms. - Page 60 Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 Service measures Task Interval Component Description Description Roller mounting Tighten all fasteners. Tighten all fasteners on clamping bars and cable Cable mounting clamps. Towing device Exchange worn parts if necessary.
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Page 61: Wearing Parts
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 8.2.6 Wearing parts Wearing parts are excluded from the warranty. This includes: All trolley rollers including main rollers, horizontal guide rollers, anti-lift rollers. Cable (expander and/or shock cord) on the damping devices. -
Page 62: Repeat Inspections
If qualified service technicians from the system operator perform the repairs themselves, all information contained in these operating instructions must be observed. Conductix-Wampfler accepts no liability or responsibility for damages and production faults that result from failure to follow these operating instructions. -
Page 63: Troubleshooting
Exchange the corresponding Malfunction component components (bending, tear, wear) The cause of overstress must be identified and corrected. If injury to person and property can occur during breakdowns then Conductix-Wampfler must be informed immediately. MAL0300-0004c-EN www.conductix.com translated document Page 63 of 70... -
Page 64: Disassembly And Disposal
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 10 Disassembly and disposal 10.1 Safety Danger of injury due to improper disassembly! Stored energy, sharp components, points, and edges on and in the festoon system or the tools needed can cause injury. -
Page 65: Disassembly
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 10.2 Disassembly After the system is no longer in use, the festoon system must be disassembled and environmentally friendly disposal carried out. Before starting disassembly: Remove operating and auxiliary materials as well as residual processing material, and dispose of them in an environmentally ... -
Page 66: Documentation For Electrical Equipment
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 10.4 Documentation for electrical equipment See separate electrical documentation. 10.5 Spare parts list Keeping a stock of the most essential spare and wear parts at the place of installation ensures constant operational readiness of the system. -
Page 67: Product Observations
Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 10.6 Product observations We strive to observe our products after delivery in order to further improve them and better meet your needs. Please use the form on the following pages to communicate your experiences and issues with us that could be of interest for our improvement process. - Page 68 Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 MAL0300-0004c-EN www.conductix.com translated document Page 68 of 70...
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Page 69: Final Acceptance Certificate (Pfr05-15-02-E)
Needed installation time (in h): Needed travel time (in h): The installation of above mentioned project has been completed today by Conductix-Wampfler and meets all requirements for final acceptance. From today, the risk is transferred to the customer The acceptance has been confirmed on a separate Customer specific acceptance protocol. - Page 70 Mounting Instructions Festoon Systems for I-Beams Programs 0365 / 0370 / 0375 Conductix-Wampfler GmbH Phone: +49 (0) 7621 662-0 Rheinstraße 27 + 33 Fax: +49 (0) 7621 662-144 79576 Weil am Rhein - Märkt info.de@conductix.com Germany www.conductix.com Importer for the United Kingdom: Conductix-Wampfler Ltd.
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